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I've had DSS problems as long as I can remember. Had a new Carrier 2 speed installed a little less than 2 years ago... still has strange odor, definitely from the coil. Decided to take some close-up pictures of the coil. Full of white residue of some sort (probably causing the DSS). Has a 5" Carrier Merv-10 filter. My guess is oxidation? Here's some pictures:

DSS can be totally eliminated be using a phoenolic coating on the evap coil ... have over 75 coated coils installed to correct and prevent DSS and to date not one call back ... research shows that DSS is a mold somewhere in your house structure and you will find it again when you put new coils in and it comes baxk ... coating seals out the white aluminum oxide formed by the inferior aluminum recycled from used coke cans ... that's the way it is ... buy a new coil get it coated and use an expansion valve and do not oversize the coil and you will again breathe ordorless air ... the DSS MOLD has not shown to be a health hazard nor has it been proven how to get it out of your house ... i have a large house and have DSS in one zone only ... that zone has a coated coil and the other 3 zones do not ...

You say: "i have a large house and have DSS in one zone only ... that zone has a coated coil and the other 3 zones do not ..." yet earlier in your reply you say coated coils is the only way to get rid of DSS. This seems to be contradictory.

You know anyone in Austin, TX that installs coated coils? If I give you the Carrier model, can you ship me one? I sure would like to be your 76th happy customer!

I USE A 2 STAGE COIL THAT will shift from low stage to give you more humidity in low and a better balance uverall. i will get the model numbers and then we look at the cost ... i assume you are on the new refrigerant.
i need your model of the furnace coil and condenser ... do you have an expansion valve now?

There was a hint in my previous post... "Dirty Sock Sydrome", an odor that smells "odd" from bacteria build up on a coil, that is noticeable when coil is wet (or is just drying out, not sure)... or caused by aluminum oxide (corrosion of cheap fins made from cheap soda cans). No one seems to know for sure, but it happens mostly in heat pumps, and seemingly only with select manufacturers. Coil cleaning doesn't solve the problem.